JP2010194863A - Resin molding of carbon fiber fabric sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a resin molding of a carbon fiber fabric sheet efficiently mass-produced and excelling in design and decorativeness. <P>SOLUTION: The resin molding of the carbon fiber fabric sheet is formed by laminating transparent thermoplastic resin films 3 on both sides of a fabric sheet 2 obtained by weaving carbon fiber 1, to prepare a film laminated fabric sheet 4, cutting the film laminated fabric sheet to the product shape to prepare a film laminated fabric sheet shape material 7, and covering the surface and edges 8 of this shape material with a transparent resin body 9 by injection molding to form the resin molding of the carbon fiber fabric sheet. A second resin molding of the carbon fiber fabric sheet can also be manufactured by injection-molding a resin body 18 for a constitutive body on the back face of the shape material. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a resin molded body of a woven fabric sheet made of carbon fiber. More specifically, the present invention relates to a resin molded body of a carbon fiber woven sheet in which a woven pattern made of carbon fiber can be visually seen through a resin molding and a cut edge is covered with a resin.

  Carbon fiber reinforced plastic (abbreviated as “CFRP” carbon fiber reinforced plastics) is a composite material in which carbon fiber is put into a resin to improve the strength. It is well known that CFRP is widely used in various fields such as aircraft and automobile. Since this carbon fiber is lightweight and strong, it is applied to various fields as described above, particularly as a surface material. The CFRP is characterized by light weight, excellent wear resistance, heat resistance, acid resistance, electrical conductivity, etc., and high specific strength and specific rigidity. Furthermore, various products of different types have been developed depending on the manufacturing form.

  Products using this carbon fiber as a woven fabric sheet have a smooth surface and excellent design, and an embossed pattern or the like can be applied to make various products with excellent design and decorating properties. Recently, in consideration of this carbon fiber pattern, a material that has been made easy to handle by applying a thermoplastic resin film to the outer surface has been proposed so that a fabric sheet can be easily used in consideration of design.

  This material is designed to have a sense of depth due to the concavo-convex pattern of the embossed part by applying a flat printed pattern to the film. Further, since the strength is not ensured only by applying a thermoplastic resin film, a molded body in which a curable transparent resin body is applied to the surface has also been proposed. An example of such a conventional technique will be described. A thermoplastic resin film is laminated on the front and back surfaces of a carbon fiber reinforced thermoplastic resin sheet, which is a prepreg made of a thermosetting resin made of epoxy resin or the like and carbon fiber. Molded products are known (see, for example, Patent Document 1). This molded product is made so as not to impair the smoothness and design of the surface, particularly in a high temperature environment.

  Further, although the same technique as described above, a technique for manufacturing a decorative sheet by joining a transparent permeable sheet made of a thermoplastic resin and a carbon fiber-containing woven sheet by a hot press is known (for example, (See Patent Documents 2 and 3). It is characterized by a uniform thickness of the woven sheet and a transparent pattern. Furthermore, a technique is also known in which a transparent thermoplastic resin (transmission sheet) is preheated and pressed into a fabric sheet and integrated into a fabric decorative resin product (for example, see Patent Document 4).

  Furthermore, a technique is also known in which a thermoplastic sheet is laminated on both sides of a carbon fiber cloth to form a laminated sheet, and the laminated sheet is placed in a mold to form a molded body having a required shape (for example, Patent Document 5). reference). In this technique, a structural member is integrated with this formed body by injection molding to form a resin molded body as a product. Furthermore, a composite sheet obtained by compositely reinforcing a thermoplastic fiber such as a transparent polycarbonate resin on a reinforced fiber fabric sheet and a transparent resin such as a transparent methacrylic resin laminated on the surface by heating / pressurizing are also known ( For example, see Patent Document 6).

JP 10-138354 A JP 2005-169803 A JP 2005-169801 A Japanese Patent No. 4051396 JP 2002-254469 A JP 11-348191 A

  Each of the conventional techniques described above relates to a technique in which a material function such as a film resin laminated on a carbon fiber woven sheet or a transparent resin laminated thereon is enhanced. However, there is still room for improvement in commercializing this material, especially in mass production. In practical use, when these laminated products are applied to a product, they must be processed according to the target product.

  In this processing, since the carbon fiber is impregnated with the resin, the fabric sheet is compressed when hot pressure is applied, and the carbon fiber becomes flat. Since the laminated film also maintains a smooth state, the woven sheet laminated with the film becomes a cured product in this state even after cutting. However, for example, when this material is formed into a predetermined shape by punching or the like, the carbon fiber is exposed on the cut surface, so that a smooth process for fixing the material is required. The problem is thus the processing of the edges, not the surface. The laminated material is usually cut into an arbitrary shape as described above.

  The cut edge of the carbon fiber is exposed at the cut edge. The exposed carbon fibers are unraveled and are in a “frayed” state, with some protruding beyond the edge. For this reason, the cut laminated fabric sheet is subjected to a treatment for flattening the edge portion in the subsequent production process. In addition, since such a process is required, an object of cutting the laminated product and using it as a product as it is is limited and limited in terms of cost. However, there are a wide variety of target products, and it has been desired that any target product can be obtained in large quantities as a product that can be used as it is without impairing the design.

The present invention was devised to solve the problems based on the technical background as described above, and achieves the following object.
An object of the present invention is to provide a resin molded body of a carbon fiber woven sheet that is easy to manufacture a large amount of a carbon fiber woven sheet and is excellent in design and decoration.

The present invention takes the following means in order to achieve the object.
The resin molded body of the carbon fiber fabric sheet of the present invention 1 is a film-laminated fabric comprising a fabric sheet obtained by weaving carbon fibers and a thermoplastic resin film laminated so as to sandwich both sides of the fabric sheet. A film laminated woven sheet shaped product formed by cutting a sheet into a required shape, and a transparent thermoplastic resin that covers the surface of the film laminated woven sheet shaped product and the edge formed by the cutting by injection molding It consists of a transparent resin body.

  The resin-molded body of the carbon fiber woven sheet according to the second aspect of the present invention is characterized in that, in the first aspect, the film-laminated woven sheet formed by cutting into the required shape is formed by press cutting.

  The resin molded body of the carbon fiber woven sheet according to the third aspect of the present invention is the sheet according to the first aspect, wherein the woven sheet is formed by regularly intersecting a combination of longitudinal carbon fibers and lateral carbon fibers. It is characterized by that.

  The resin molded body of the carbon fiber fabric sheet of the present invention 4 is characterized in that, in the present invention 3, the fabric sheet is a plain weave fabric sheet.

  The resin molded body of the carbon fiber woven sheet according to the present invention 5 is the resin molded body according to any of the first to fourth aspects, wherein the resin molded body has the transparent resin body on one surface of the film-laminated fabric sheet-shaped article, and the film-laminated fabric sheet. A molded article configured to cover the film laminated fabric sheet shaped article by joining the transparent resin body or a thermoplastic resin body made of another thermoplastic resin different from the transparent resin body to the other surface of the shaped article by injection molding. It is characterized by being.

  The resin molded body of the carbon fiber fabric sheet of the present invention 6 is characterized in that, in the present invention 5, the thermoplastic resin body is a colored or black resin body.

  The resin molded body of the carbon fiber woven fabric sheet of the present invention 7 in the present invention 5, the transparent resin body or the thermoplastic resin body bonded to the other surface is integrally formed with a part for attaching to the other side. It is the resin body for structure which is characterized by the above-mentioned.

  As described above in detail, the resin molded body of the carbon fiber woven sheet of the present invention is transparent to the film-laminated woven sheet as it is after cutting, without requiring a special step of smoothing the edge. It is now possible to obtain a molded body in which a woven sheet is integrated by injection-molding a functional resin including not only the surface but also the edge. As a result, the molded body based on the carbon fiber woven sheet is superior in design and decoration without damaging the design and decoration, and can be mass-produced, enabling efficient production of products. became.

FIG. 1 is a cross-sectional view schematically showing a resin molded body of a carbon fiber woven sheet. FIG. 2 is a partial plan view schematically showing a film-laminated woven sheet. FIG. 3 is a partial cross-sectional view showing a resin molded body of a carbon fiber fabric sheet. FIG. 4 is a partial cross-sectional view showing a bent configuration of a resin molded body of a carbon fiber fabric sheet. FIG. 5 is a modification of FIG. 3, and is a partial cross-sectional view showing a configuration in which an edge portion of a resin molded body of a carbon fiber woven sheet is formed in an R shape, including a mold. FIG. 6 is a modification of FIG. 4, and is a partial cross-sectional view showing a configuration in which the edge portion of the resin molded body of the carbon fiber woven fabric sheet has an R shape, including a mold. FIG. 7 is an external view showing a box-type cover of an electronic device in the configuration example of FIGS. 4 and 6. FIG. 8 is a partial cross-sectional view showing another embodiment of a resin molded body of a carbon fiber woven sheet in which another thermoplastic resin body is integrated on the back side by injection molding.

  The present invention was conceived as a molded body that increases the productivity efficiency in consideration of commercialization of a carbon fiber woven sheet. Hereinafter, embodiments of the present invention will be described with reference to the drawings. Carbon fiber is rarely used alone as described above, and is used as a carbon fiber reinforced plastic (CFRP) formed by impregnating resin and heat-curing, but in the description of this embodiment, this CFRP is included. In a broad sense, it will be referred to as carbon fiber. The carbon fiber is handled as an intermediate material in which the fibers are aligned in one direction, a so-called prepreg.

  FIG. 1 is a cross-sectional view schematically showing a resin molded body of a carbon fiber woven sheet. FIG. 2 is a partial plan view schematically showing a film-laminated woven sheet. A molded body of the woven sheet 2 forming a pattern (plain weave) woven by combining the longitudinal fibers 1a of the longitudinal carbon fibers 1 in FIG. It is explanatory drawing shown with a cross section typically. The woven fabric sheet 2 of the carbon fiber 1 has a curved step at the intersection, and the surface is not flat. The carbon fiber 1 is a type constituting a reinforcing fiber, and other similar ones include aramid fibers and glass fibers. However, most industrial products are made of carbon fiber 1. The carbon fiber 1 is produced by firing polyacrylolyl, pitch, rayon, etc., as is known for aircraft materials of various types, and is generally widely used as a structural material. Material.

  The form of the woven fabric sheet 2 woven using the carbon fiber 1 as a raw material is the same as a plain weave, twill weave, satin weave or the like generally known as a cloth, and is based on what is known as a Mihara texture. In this embodiment, the fabric sheet 2 will be described as a plain weave. Plain weaving is a conventionally known and plain woven fabric, which is woven by combining prepreg-like longitudinal flat carbon fibers and transverse flat carbon fibers so that they cross alternately. Is. A transparent thermoplastic resin film 3 is laminated and bonded to both surfaces of the woven sheet 2 to form a film-laminated woven sheet 4.

  This film laminating method is performed by heating and pressurizing and can be stably treated as a surface material. By covering the woven fabric sheet 2 of the carbon fiber 1 with the film 3 in this way, the unevenness of the carbon fiber 1 is reduced and the surface becomes smooth. Therefore, the carbon fiber 1 can be stably held, and can be handled as a stable material that does not impair the design and decoration properties. The film-laminated woven sheet 4 has a flexible structure, but normally, the carbon fiber 1 is easy to handle because it is impregnated with a resin. The carbon fiber 1 is sandwiched between films 3 and laminated and bonded by a press.

  In this lamination bonding method, it is preferable to perform press working at a predetermined temperature (for example, a temperature of 178 ° C.). Further, as shown in Patent Document 6, a method of continuously bonding using a heating / pressurizing roll may be used. The film 3 has a thin thickness of, for example, 0.13 mm. In addition, it is preferable that the thickness of a film is 0.1 mm or more and 2.5 mm or less. When the film 3 is bonded, the film 3 is bonded following the surface of the woven sheet 2, so that the surface of the film-laminated woven sheet 4 also has moderate unevenness. That is, the weaving portion becomes the concave portion 5 having a curved step as described above. The presence of the recess 5 changes the reflection of transmitted light and becomes an important element for design and decoration.

  Moreover, since the intersection part 6 which is a site | part where the carbon fiber of a vertical direction and a carbon fiber of a horizontal direction cross | intersect is a site | part which a gap | interval produces as shown in FIG. Moreover, it is a site | part which can permeate | transmit light. Thus, the film laminated fabric sheet 4 on which the film 3 is laminated is a sheet excellent in design and decoration as a surface material. Next, the film laminated fabric sheet 4 is cut into a required shape by a press cutting means such as punching in accordance with the target product to be used, and a film laminated fabric sheet shaped product 7 (hereinafter referred to as “shaped product”) is obtained. This cutting is performed by forcing the cutting blade against the surface of the fabric sheet 2 from a direction perpendicular thereto and forcibly cutting. This cutting is not necessarily cut along the plain weave direction, as shown by the shaped object 7 in FIG. 2, and is also cut along an oblique direction with respect to the weave direction.

  Thus a state in which solved edge 8 of the carbon fiber 1 is just cutting portion, a part of the exposed state protrudes outward becomes "loose". Conventionally, in order to eliminate this “fraying”, a smoothing process is performed in a separate process. However, in the present embodiment, the shape 7 in this state is inserted into a mold (not shown). After the mold is closed, a transparent thermoplastic resin (hereinafter referred to as “transparent resin”) is injected by injection molding to form a transparent thermoplastic resin body 9 (hereinafter referred to as “transparent resin body”). Although this mold configuration is based on known means, a transparent resin is injected in a state of surrounding not only the surface of the shaped object 7 but also the edge 8, and the transparent resin body 9 covering the surface of the shaped object 7 and the edge 8 is formed. It is configured to be molded. The “transparent resin” referred to in this embodiment includes those that are slightly colored as long as the shape of the fabric sheet can be seen through.

FIG. 3 is a partial cross-sectional view showing a resin molded body of a carbon fiber fabric sheet.
By forming the transparent resin body 9 as described above, a resin molded body 10 (hereinafter referred to as “resin molded body”) of the carbon fiber fabric sheet shown in FIG. 3 is obtained. The injected resin is a transparent resin, and after injection, the resin molded body 10 has a pattern of the woven fabric sheet 2 that appears as a three-dimensional pattern in an uneven shape, and has different brightness depending on the viewing direction. A unique pattern is formed by the action. The transparent resin body 9 is, for example, a resin body injected with methacrylic resin, polycarbonate resin, ABS resin, or the like. In particular, the methacrylic resin is said to be polymethyl methacrylate, and is said to be a resin having the highest transparency, and can form a resin body having a wide range of uses.

  By this injection molding, the “fray” of the edge 8 of the fabric sheet 2 is sealed and fixed in the transparent resin body 9. Therefore, when the resin molded body 10 is molded, the “frayed” portion is not exposed to the outside at all. Depending on the mold structure, a part of the “fraying” portion may be exposed to the outside. By doing in this way, it becomes possible to insert a textile sheet reliably in a metal mold | die.

  FIG. 4 is a partial cross-sectional view showing a folded configuration of a resin molded body of a carbon fiber woven sheet, and is an embodiment in the case where the shape object 7 is a product having a folded configuration. In this case, the shaped object 7 is formed by pressing, and after being pressed, it is inserted in accordance with a mold along the pressed shape. In addition, if the shape 7 is of a flexible configuration using an uncured thermoplastic resin, it may be injected after being inserted into the mold so as to match the shape of the mold. Good.

  Also in this case, as shown in FIG. 4, the transparent resin body 9 is molded by injecting the transparent resin including not only the surface but also the edge 8. 3 and 4 indicate the dividing positions of the upper and lower molds. FIG. 5 is a modification of the form shown in FIG. 3, and shows a form including a mold configuration in the case where the edge 8 of the transparent resin body 9 to be injection-molded has an R shape. If the corner 11 on the 13th side is formed in an R shape, the edge 8 of the transparent resin body 9 to be injection-molded becomes a smooth shape. The division position 14 of the upper mold 12 and the lower mold 13 is moved to a position corresponding to the R dimension on the upper mold 12 side with respect to FIG. The position is set to a substantially middle portion of the thickness of the resin molded body 10.

  FIG. 6 is a modification of the form shown in FIG. 4 in the same manner as described above, and shows a form including a mold configuration in the case where the edge part 8 of the transparent resin body 9 to be injection-molded has an R shape. As in FIG. 5, the concave portion 15 of the lower mold 13 is formed in an R shape, and the dividing position of both molds is closer to the upper mold 12 than in the example of FIG. If the dividing position is shifted and divided, the edge portion 8 of the transparent resin body 9 is formed into a smooth shape. 4 and 6, as shown in FIG. 7, the resin molded body 10 in an injection-molded state can be applied as a finished product, for example, as it is to a box-shaped cover 16 of an electronic device. Is possible. A lightweight product structure with an excellent design and decorative surface is possible.

  Since the resin molded body 10 of the carbon fiber fabric sheet described above is very lightweight and can be molded into a predetermined shape, it can be used in a wide range of applications with excellent design and decorating properties in the same form. Can be applied. As described above, it can be used for, for example, a cover of a mass-produced mobile phone, a home appliance, an electronic device, and an electric device. Furthermore, it is also possible to integrate the resin molded body 10 by, for example, injection molding a structural body (core material) for joining with another product.

  FIG. 8 is a partial cross-sectional view of a resin molded body 10a manufactured by integrating a resin body 18 for a structural body having a hook (attachment section) 17 for mounting to a counterpart product with the resin molded body 10 in the form of FIG. FIG. The resin molded body 10a is inserted into a mold in which a cavity capable of forming the hooking portion 17 and the like so as to have a predetermined shape is inserted into the resin molded body 10 having the above-described form, and the resin for the structural body is inserted into the above-described resin This is obtained by injecting into the cavity on the back side of the shaped object 7 on the side opposite to the transparent resin body 9 and molding the constituent resin body 18. By such a method, it is possible to obtain the second resin molded body 10a which is another embodiment of the resin molded body. In this case, the structural body resin body 18 may be one in which a transparent resin is injection-molded, or may be one in which another thermoplastic resin is injection-molded. Further, the edge portion 8 may be covered with a transparent resin body 18 for structural members. Further, the second resin molding may be molded by an injection molding method called so-called two-color molding.

  Further, the second resin molded body may be obtained by partially injection-molding the structural body resin body only in the portion of the resin molded body 10 required for attachment in order to reduce the weight. Needless to say, the second resin molded body can also be applied to the resin molded body having the structure shown in FIGS.

  Further, the resin molded body may be coated with the other side (back side) of the transparent resin body 9 by injection molding with another colored or black thermoplastic resin body by two-color molding or the like. A 3rd resin molding can be obtained by such a method. The third resin molded body may have the same shape as the resin molded body 10a of FIG. 8, or may have a shape in which the hook portion 17 is not provided. This third resin molded body can be made into a resin molded body further excellent in design and decorating properties due to the contrast between the color of the fabric sheet 2 and the color of the other thermoplastic resin on the back side. For example, the third resin molded body may have a color such as an edge that is different from the color of the fabric sheet 2. In addition, the color of this other thermoplastic resin body is good in the color of the fabric sheet 2, the color which makes a shape stand out more, the color opposite to the color of the fabric sheet 2, etc.

  Further, in this third resin molded body, in order to reduce the weight, the structural body resin body may be partially injection-molded only in a necessary portion of the resin molded body 10 such as the vicinity of the edge. It goes without saying that this third resin molded body can also be applied to the resin molded body having the configuration shown in FIGS.

  The resin molded body formed in this way has a structure in which a carbon fiber woven sheet is laminated with a film and a transparent resin, is subjected to heat pressure, and is firmly laminated and bonded by injection molding. There is no risk of doing so, and a stable product that can be mass-produced can be obtained.

  In addition to aircraft and automobiles, it can also be applied to electrical and electronic equipment. For example, a mobile phone cover, a personal computer (PC), a cover for audio equipment, a housing, and the like. It can also be applied to products that place particular emphasis on design.

1: Carbon fiber 2: Woven sheet 3: Film 4: Film laminated woven sheet 7: Shaped film laminated woven sheet 8: Edge 9: Transparent thermoplastic resin body 10: Resin molded body of carbon fiber woven sheet

Claims (7)

Film laminated fabric sheet formed by cutting a film laminated fabric sheet composed of a fabric sheet obtained by weaving carbon fibers and a thermoplastic resin film laminated so as to sandwich both sides of the fabric sheet into a required shape With a shape,
A resin molded body of a carbon fiber woven sheet comprising: a transparent resin body made of a transparent thermoplastic resin that covers the surface of the film-laminated woven sheet shaped article and the edge formed by cutting by injection molding. In the resin molded product of the carbon fiber fabric sheet according to claim 1,
The film-laminated woven sheet shaped product formed by cutting into the required shape is formed by press cutting. In the resin molded product of the carbon fiber fabric sheet according to claim 1,
The woven sheet is a sheet formed by regularly intersecting and combining longitudinal carbon fibers and transverse carbon fibers. A resin molded body of a carbon fiber woven sheet. In the resin molded product of the carbon fiber fabric sheet according to claim 3,
The woven fabric sheet is a plain woven woven fabric sheet. A carbon fiber woven fabric sheet resin molding. In the resin molded body of the carbon fiber fabric sheet according to any one of claims 1 to 4,
The resin molded body has the transparent resin body on one surface of the film-laminated woven sheet shaped product, and the other surface different from the transparent resin body or the transparent resin body on the other surface of the film-laminated woven sheet shaped material. A resin molded body of a carbon fiber woven sheet, characterized in that it is a molded body in which a thermoplastic resin body made of a plastic resin is joined by injection molding to cover the shape of the film-laminated fabric sheet. In the resin molded body of the carbon fiber fabric sheet according to claim 5,
The thermoplastic resin body is a colored or black resin body. A resin molded body of a carbon fiber fabric sheet. In the resin molded body of the carbon fiber fabric sheet according to claim 5,
The transparent resin body or the thermoplastic resin body to be joined to the other surface is a resin body for a structural body in which a portion to be attached to another is integrally formed. Resin molded body.

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